Laundering system

ABSTRACT

A laundering and finishing system for garments (such as no-iron garments) collected from a number of user sources of soiled garments includes a hanging zone, a washing zone including spray assemblies, a drying zone, and a conveyor network extending from the hanging station through the washing and drying zones, the conveyor network being adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in the zones, the hanging zone being arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of the conveyor network, and the conveyor network being further adapted to discharge the garments in the same serial order so that garments originating from different sources of soiled garments are not mixed.

United States Patent [151 3,686,899 Rosenteld et al. Aug. 29, 1972 [54] LAUNDERING SYSTEM FOREIGN PATENTS OR APPLICATIONS [72] Inventors: Howard Rosenfeld, New York, 980,113 12/1950 France ..68/

N.Y.; Justin J. Wetzler, Evanston,

Ill.

Primary Examiner-Walter A. Scheel Assistant Examiner--Philip R. Coe

73 Assignee: The Linen Supply Association of America, Miami Beach, Fla Attorney J. N. Williams [22] Filed: July 16, 1970 [57] ABSTRACT [21] A L N 55,463 A laundering and finishing system for garments (such as no-iron garments) collected from a number of user sources of soiled garments includes a hanging zone, a U-So Cl. R, 10, 20, zone including pray assemblies 3 68/205 R zone, and a conveyor network extending from the [51] Int. Cl. ..D06t '31/00 hanging station through the washing and drying zones, [58] Field of Search.....68l3 R, 20, 205 R, 10; 69/23; the conveyor network being adapted to support in- 99/261, 443 C dividual garments on hangers to hang loosely for washing and wrinkle-free drying in the zones, the [56] References Cit d hanging zone being arranged to enable a worker to hang soiled garments from one user source at a time in UNTTED STATES NT serial order upon an initial conveyor of the conveyor network, and the conveyor network being further 1,757,702 5/1930 Coady ..68/3 R adapted to discharge the garments in the Same serial 2,902,138 9/1959 Oelkers ..68/3 R X order so that garments originating from different Belms C sources of so ed ga m nts an: not ix d- 3,550,169 12/1970 Forse ..68/3 R X 1,220,308 3/1917 Young et al. ..68/l0 24 Claim, 12 Drawing Figures a so so 92 91 f i f ii iiflr he 2 L K IO 1 OjAg/A//gZ/N 92 E1- 5 MINUTES L vii ming 1:: iii 5%,? LI: 96

I8 9 a n n" T 9? l2 s r *za/v?"" if igigg g ffl 2, I a INUTES I H 97 C 1 Wait g j 1; 26 97 4 F" T [52 O 42 h K M ZQ/PEFI' MIN. 1 I 90 TERM/M 4 APART l/VSPECT/ON a IB'QIPART ffi-FEQF'FEQZQ PA/vrs swam |P4CKA6MIG l sumo/v f 36 {I56 2 4 EU U U U i i L ay/am Ml/V J r 1 1 T {BETWEEN crjvrms OFF/(gs) a l 1 L -1 2*- ISTAT/GW I a I PATENTHIMIB I saw 2 or a FIG 8 PATENTEBnuczs m2 sum 5 or a FIG 5 LAUNDERING SYSTEM This invention relates to commercial laundering and finishing systems for rental garments and the like.

An object of this invention is to provide an improved and automated laundering and finishing system for processing garments and the like in an orderly manner.

Another object is to provide commercial laundering systems with reduced solids and water usage and hence very low pollutant discharge levels.

Among other objects are to provide commercial laundering systems which: have improved garment cleaning; process heavy and light soil, colored and white, and differently configured garments together; handles, launders and finishes no-iron garments without pressing; can provide sanitary, and even sterile, sealed package garments and lintfree sealed package garments; reduce water and detergent-consumption; reduce man-hour requirements (while improving working conditions); and, reduce garment abuse such as fiber wear; and, simplify customer make up for delivery.

A specific object is to provide a commercial laundering system which is fully automated between receipt of soiled garments from a customer and production of clean, ready to wear garments for delivery back to the customer. The invention features a laundering and finishing system for garments (such as no-iron garments) collected from a number of user sources of soiled garments comprising, in combination, a hanging zone, a washing zone, a drying zone, and a conveyor network extending from the hanging station through the washing and drying zones; the conveyor network is adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in the zones, the hanging zone is arranged to enable a worker to hand soiled garments from one user source at a time in serial order upon an initial conveyor of the conveyor network, and the conveyor network is further adapted to discharge the garments in the same serial order so that garments originating from different sources of soiled garments are not mixed. The system thereby enables rapid automatic processing including washing, drying, and packaging of the garments, such as rental garments, with the serial order of the garments maintained throughout the system, the time required for processing each garment significantly reduced, and the garments provided in finished form of fully pressed ready-towear appearence.

A preferred laundering system comprises, successively arranged, a hanging zone, an inspection and prespotting zone, a soak zone, and a spray zone, all preceding the drying zone. At the pre-spotting zone, spot-loosening solution is applied to the garments. The pre-spotting zone and the soak tank are preferably separated by a delaying zone wherein the spot-loosenpreceding garments down into the soak tank. The conveyor system may continue through the soak tank, thus forcing the garments forward at a predetermined rate through the soak tank while the garments remain immersed. In one alternative embodiment, the soak tank is in the form of a J with arriving garments being supplied to the top of the high side of the tank and the weight of garments, including the added weight of arriving garments, serving to force-soak garments around the curve of the tank and eventually out through the low side of the tank. For conveying the garments through the J-shaped tank, the guide means may simply be a slick rail upon which the hangers can slide as the garments progress through the tank. in another embodiment, a low pressure spray environment is used in lieu of the soak tank, as the soak zone.

The garments are generally conveyed through these zones arranged on hangers oriented with the long directions of the hangers at right angles to the conveyor line. In a preferred spray zone, however, the garments are turned so that the long direction of the hangers is aligned with the direction of the conveyor. This spray zone has water spray assemblies positioned along the broad sides of the garments. These water spray assemblies are arranged successively along the path of travel of the garment to define a plurality of spray stations of which the last spray station is a fresh water rinse, and the remaining spray stations include alternating wash and rinse stations and, if desired, additional stations such as for bleaching and for applying bacteria-destroying solutions. The water spray assemblies are preferably arranged so as to provide relative movement between these assemblies and the garments during washing. For example, the water spray assemblies may be moveable relative to a stationary garment, such as one or more spray lines mounted to rotate in a plane generally parallel to the plane of the garment. The garment may be kept stationary at each station, as by timing means in a conveyor system extending to the washing station which stops each garment adjacent a water spray assembly for predetermined spraying time. Alternatively, the garment may also be mounted for moving, vertically relative to spray assemblies.

The spray assemblies arranged on opposite broad sides of the garment are preferably arranged to oppose one another sufficient to prevent. force-through of dirt, loosened in a soaking zone upstream of the spray zone, and yet still provide some relative movement or fluffing of the garment.

In a preferred embodiment, there are a plurality of multiple parallel conveyors through the spray zone with a plurality of parallel spray stations arranged along each conveyor, a single conveyor line feeds the garments to a divider and hence serially into the multiple conveyor zone, and a merger device following this spray zone merges the garments again onto a single conveyor line in identical serial order to that preceding the spraying zone. A single soak tank precedes and serves all parallel spray stations.

A preferred drying zone, for soiled garments having a memory for a heat set smooth flat pressed form, succeeds the spray zone and includes means for maintaining the temperature of the drying zone below the predetermined heat set temperature of the fabric of the garments and above the temperature of the washing zone so the garments are restored to a heat-set smooth flat press form. The garments enter this zone dripping wet so as also to provide high humidity in the zone, which may be further increased by adding steam.

The discharge zone, for garments to be delivered folded, preferably includes a plurality of folder devices, each adapted to fold a different type of garment, and includes a sensor system for selecting garments from the single conveyor line preceding the folders and dispensing the garment to the proper folder. For example, if the hangers each comprise a lower hanger rung for trousers and a sheared upper rung for shoulders of other garments, then a sensing system comprising photo-optic beam sources and sensors for (a) the space between the lower and upper rods and (b) a position spaced below the lower rods greater than a predetermined distance corresponding to the bottom edge of a jacket, can be used to categorize the garments in ac cordance with whether both or either one of the light beams are interupted. The three usual categories would be laboratory-length coats, trousers, and shirts or jackets. The system preferably further includes a merger device adapted to merge the outputs of the folder devices back into the serial order corresponding to the original order of the garments. The folder devices may be constructed to fold the hangers within the garments. In lieu of folding devices, laundered and finished garments may be delivered to customers on hangers.

The invention further features a pollution-reducing commercial laundering system in which a soak zone and a washing zone, through which garments are conveyed on hangers, each has a recycle stage which is adapted to collect the used liquids, regenerate wash and rinse liquids therefrom by filtering, heating, adding chemicals, etc., and return the water for soaking, washing, or rinsing. The washing zone further includes a last rinse station which is adapted to receive fresh water and to collect used water from that last rinse station to be directed on demand to the soaking zone, the wash stations, or the rinse stations. The soaking zone is also, as are all systems, continually recirculated, and, at a rate of processing 300 garments per hour, need be drained and the water changed only about once a week. The efficiency of this laundering system further allows less detergents, soaps, and other non-degradable materials to be used as well as decreasing the total amount of polluted water discharge.

Furthermore, since the system is automatic and the garments serially conveyed between the hanging and pre-spotting station and the makeup zone where packaged garments are made up according to customer demands, the entire environment surrounding the automatic zones may be sealed, and thus kept lint free or sterile as required. In addition, sterile sealed garments can be provided if, for example, bacteria-destroying solutions are applied in the washing zone, the dry temperatures are at sterilizing temperatures on the order of 300 F, and the packaging machines are adapted to package the garments in sealed-sterile packages.

Other objects, features and advantages will be apparent to one skilled in the art from the following description of preferred embodiments of the invention, taken together with the attached drawings thereof, in which:

FIG. 1 is a layout drawing of a garment processing system embodying the present invention; the

FIG. 2 is a schematic illustration of check-in and hanging zones;

FIG. 3 is a schematic illustration of an inspection zone;

FIG. 4 is a diagrammatic perspective illustration of a soak tank;

FIG. 4A is a cutaway view of a section of the soak tank of Fig. 4 showing garments butted together and hence maintained fully immersed beneath the soak fluids in the tank;

FIG. 5 is an elevational view of a sprayer section arrangement for the stations of the spray zone;

FIG. 6 is a sectional view of the sprayer of Fig. 5;

FIG. 7 is a water recirculation diagram for the spray zone;

FIG. 8 is a schematic view of a photoelectric arrangement for guiding garments to the correct folding station;

FIG. 9 is a diagrammatic cross-sectional illustration of another soak tank; and,

FIGS. 10 and 11 are other sprayer station arrangements.

The figures show a garment handling system 10 comprising a hanging or check-in zone 12, an inspection zone 14 including a pre-spotting station 16, a delay zone 18, a laundering zone 20 consisting of a soak zone 22 and a spray zone 24, a drying zone 26, and a discharge zone 30 including a hanging make-up station 31, or, optionally folding stations 32, 33, 34, and a packing station 36. For purposes of illustration, a commercial laundering system will be described, designed to launder rental garments at a rate of about 300 garments per hour.

Referring to FIGS. 1 and 2, at the hanging or checkin station 12, individual customer bundles 40, filled with soiled garments, are conveyed to the check-in station by a bag conveyor 41, and are released by the check-in worker, one of three workers required, onto a work table 42. Disposable hangers 43 are fed to the hanging station from a hanger magazine 44 the hangers being mounted firmly and substantially immobile on a hanger carrier 52 driven by a conveyor 45. A single hanger design may be used for all types of garmentsshirts, pants, dresses, trousers or coats. The hangers may be of disposable material (e.g., fine coated wire or cardboard).

Garments 46 worn on the shoulders are hung over the top bar 47 of the hanger, whereas trousers are hung from the bottom bar 48. The garments are fed, at a rate of 20 inches per minute, spaced 4 inches apart as indicated (hanger to hanger) on the conveyor 45. Thus, in the few seconds required to hang the garment, the hanger is moving only slightly, and the total rate of 12 seconds per garment, or 300 garments per hour requires only one worker at this station. The conveyor 45, shown as a double rope conveyor, may be of any design-e.g., also a screw conveyor, or a chain conveyor. The depleted customer bundle bags are led away on conveyor 49.

The illustrated hanging station is also a counting station and the operator, in addition to hanging garments, will identify customer number and e.g., flag the first and last garment of each customer in a manner which can be later read out at the makeup zones. In addition, information may be fed into a console 51 such as the type of garment, its color, or its soil level (e.g., to identify garments unusually heavily soiled). The garment, once hung, is now permanently sequenced, which sequency will continue throughout the system.

As observed, this system takes advantage of soiled garment customer pre-sort and maintains segregation by customer throughout the process. The continuous, steady flow makes possible the direct labor savings of this system over conventional batch systems, washingon-a-hanger" being the key to continuous flow and to maintenance of customer segregation.

The garments, on conveyor 45, still at 20 inches per minute and 4 inches separation, are conveyed to the inspection zone 14, shown in FIG. 3, and delivered singly to a turning mechanism including a motor 56, where the garment makes one or more complete turns in front r of the inspector in a total elapsed time of 12 seconds so that theentire surface of the garment is visible. In lieu of motor 56, the garment could be gravity fed down a helical screw or pigs tai to cause this turning. The inspector, the second worker in the system, pre-spots bad stains (i.e., by spraying with an appropriate stainloosening solvent) while examining the garment. The collars of all garments, as well as the sides of garments, such as laboratory coats, and the areas around the coat and pants pockets may be automatically pre-spotted, either before or after the visual inspection zone. The inspector has a number of guns suspended from above,

, including a suction gun 58 for removing foreign matter from pockets, and a spotting gun 60 for prespotting particularly difficult stains such as blood and grease.

The inspector also identifies garments in need of repairs (tears, buttons missing) and tags the garment (e.g., by pulling down a tab on the hanger, or marking a colored spot on the hanger) or the disposable hanger carrying the garment for subsequent diversion to a repair station at the end of the line. The garment will not be removed from the line, however. Likewise, if the garment is to be replaced, another signal will be placed on the hanger. This replacement and/or repair will occur in the makeup zone after the laundering cycle is complete.

Since six to ten seconds will be ample for this operation, one inspector can easily handle the three hundred garments per hour anticipated of the check-in operator.

The hanger is passed out of the zone on conveyor 61, where the spacing between the garments is reduced to 3.2 inches in the illustrated embodiment, and the speed of conveyor 61 through the delay zone" 18 is also reduced to 16 inches per minute in the illustrated embodiment. In the illustrated system, a cycle time of 30 minutes, which is a desireable setting time for the solvents or other cleaning agents applied at the prespotting station, is required to transport the garments between the inspection station and the soak tank. In general, about 15-45 minutes should elapse between pre-spotting and the soak tank to achieve maximum benefit from the applied solvent.

Conveyor 61 delivers the garments to the soak zone 22 of laundering zone 20, shown in FIG. 4, which, in the illustrated embodiment, comprises a soak tank 62 in the soak zone, the dirt is loosened but not removed, since there is no mechanical action in the soak tank, except for a slow drain into a filter system, which removes the heaviest dirt which actually comes off during soaking, and, a concurrent slow make up of water. Any bleeding of color or loosening of dirt from the fabric is filtered or chemically removed through the continuous filtration and recycling system, shown schematically in FIG. 7. Because of the absence of mechanical action in the soak tank, the soak time, temperature, and deter gents for the tank may be chosen in accordance with the worst soiled garments, and hence heavy and light soil garments treated together, since excessive soaking conditions will do no harm to the light soil. The speed of the soak tank can then be kept constant irrespective of the soil condition of the garments. g 3 Referring particularly to FIG. 4, the garments 46 at pre-wet by sprayers 64, which may apply either water, or a soap or detergent solution to the garments prior to their entering the soak tank. Conveyor 61 delivers the wetted garments 46 to conveyor 65, which passes the garments, in butting relation, over a lip 68 into and through the tank. The pre-wetting prevents air bubbles and air bombing and thus retards the tendency of the garments to float to the surface. The weight of succeeding pre-wetted garments causes each garment to be immersed in the soak tank. In addition, since the spacing between the garments in the tank is reduced to aboutv inch between hangers, the garments, abutting one another, and the entire conveyor system also, if desired, remain immersed in the soak fluid 69 in the soak tank. A useful soaking time for garments in this tank is on the order of 60 minutes. Thus, in a system processing 300 garments per hour, an exemplary soak tank, utilizing a U-type garment pass therethrough as shown, would convey garments, at inch spacing, at a rate of about 2 inch per minute, along a total conveyor path through the tank of about 12.5 feet.

The detergents and soaps utilized in the soak zone are conventional, and a temperature of about 160l "F is preferred. If most of the garments are colored, one may lower the temperature down to F and increase the time in the tank (in which event a larger tank will maintain the speed at the worker stations and hence the garment/hour output of the system).

The garments, with dirt loosened but not yet totally removed, are conveyed out of soak zone 22 on conveyor 90 and before the spray zone 24 they are separated into a plurality of parallel lanes 91 (FIG. 1) preserving serial order and then rotated. Since the garments have been turned 90, they are now arranged in a shoulder-tdshoulder relation, so that, instead of travelling perpendicular to the conveyor, they are now parallel to the conveyor. The spacing is increased to almost 24 inches between hangers.

The avoidance of dirt force-through is most important with polyester and other manmade fibers, since such force-through entrainment could result in redeposit of dirt due to the affinity of most resins for attracting and holding dirt. In, for example, prior conventional wash wheels, the mechanical action in the wheel removes the dirt from the fabric, and the dirt goes into suspension in the liquid of the wash wheel as fine particles. In the rinse cycle, however, which is also in the wash wheels, this dirt is forced back through the garment, thus causing the garment to act as a filterunfortunately, if the garment is a polyester or other resin, or if it contains permanent-press resins, the garment will be a very good filter, trapping and holding the fine dirt particles that were originally removed. This accumulative action can result in the buildup of this redeposit, causing white fabrics to turn gradually gray and neutralizing the color of colored fabrics. The spray zone of the present system, however, reduces this accumulation by not pushing dirt through the fibers, but merely rinsing what has been previously loosened and surfaced in the soak zone.

The spray pressure from each nozzle should therefore be low enough to prevent fiber abuse and destruction (such as breakdown of fiber blends) (particularly at the bleaching station, if one) and yet sufficient to provide adequate loosened dirt removal. Line pressures on the order of 20 to 40 p.s.i. may be sufficient, and nozzle separations of about 2 to 3 inches from the garment.

Rotating rods as described have the further advantage that they provide fluffing and agitation of the garment, moving sleeves and the like out of the way so that the spray gets, e.g., underneath the sleeve, and the entire garment is thus exposed.

For processing 300 garments per hour, in a five spray station device as shown, the total time for each garment in the spray will be about 5 minutes, or 60seconds per garment per spray station. Thus, the five spray lines will each discharge one garment per minute, for a total five garments per minute discharge from the spray zone. Since the garments have been rotated 90 prior to entering the spray zone, the spacing is now 24 inches, and hence total conveyor speed through the zone is 24 inches/minute, operated, by appropriate timing means 93, as a series of fast steps (e.g., 5 seconds) between spray stations and stops (55 seconds) at each of the spray stations. Shutters or other structures may be provided not only between adjacent lanes (of. shutters 101 in FIG. 6) but also between adjacent spray stations so that the detergent spray will not mix with the rinse spray, the rinse spray will not mix with the bleach spray, etc.

The number of stations provided in each lane depends on the washing procedure desired, and, since total garment throughput depends only on time per station, the number of stations does not affect the total speed of the system. An illustrative, 8 station spraying zone might duplicate the conventional wash wheel, having, as successively arranged stations, a detergent (or soap) spray, a rinse, another detergent or soap spray, a rinse, optionally a bleach and a rinse, a sour, and, last, a clean rinse. All the rinse phases would be water. The sour phase neutralizes the bleach and stabilizes the chemical exposure of the fabric. For colored garments, the fifth or bleach station could be selectively operated in accordance with the color of the garment, e.g., by a color discriminator located at each station or by a pre-coded signal on the garment or hanger read out at the bleach station.

Each spray section, as well as the soak tank, is continually recirculated and filtered. During the recirculation cycle, additionally, the temperature and chemical constitution of the recirculation liquids are monitored, and heating or chemical additives applied as need. In

addition to reducing the possibility of re-deposit, the purification and reuse of soak and spray liquids is extremely economical and reduces the possibility of discharge of large quantities of polluted effluents from the system. Only the last rinse, pure water, would not be recirculated rinse, but this last rinse may be utilized as make-up water in the soak tank and, as required, also in the spray zones.

In FIG. 7, a recirculation system for an exemplary 5- station system is schematically illustrated. In particular, each wash and rinse station a, 1101;, l11a,l1lb, 112 is conceived to have a fluid container 114, from which fluid is slowly drained, passed through an appropriate filter 116, and pumped through a recirculating conduit by pump 118. For both wash stations 110a, 111a, and the two rinse stations 110b, lllb, the recirculating conduit 119 leads back to the fluid supply. Similarly, for soak zone 22, a filter 120 and pump 122 continually recirculate soak zone fluids. Last rinse station 112, however, is continually supplied with fresh water to its fluid supply, and filtered fluid from this last rinse station is fed through a make-up conduit 124 back to replenish the soak tank, wash stations and other rinse stations through make-up supply lines 125. The soak zone, as previously described, is periodically at least partially drained, and, if desired, wash or rinse station fluids may be used also for soak tank make-up, the wash and rinse stations then being made up from the last rinse zone or fresh water.

As shown in FIG. 1, garments are fed sequentially at divider junctions 92 to one of the five (or more) conveyors (e.g., each five consecutively arranged garments on conveyor 90 will be fed one to each conveyor) defining lanes 91, and are again merged at merging junctions 96 after completion of the spray zone cycle onto conveyor 97. The five (or more) conveyor lanes 91 thus do not cause sequence to be broken, but do allow reasonable pass-through times for garments in the spray zone.

In the spray zone, the garments are sprayed to remove dirt previously loosened in the soak zone. One suitable sprayer system is shown in FIGS. 5 and 6, which may be duplicated for each station in each lane. Two rotating rods 98a, 98b and 99a, 991:, each having four spaced nozzles 100, are located on each side of the garment, and are sized so as to cover the complete area. Each nozzle may be either straight or pulsating and all nozzles are sized to deliver overlapping sprays so as to cover completely the exposed garment surfaces. The nozzles on opposed rods 98a, 99a are generally arranged to provide opposing sprays, since, in general opposition, or near opposition, tends to prevent spray from the nozzles from forcing dirt through and onto the garment where it could become entrained. The more perfect the opposition of the nozzles on opposite sides of the garment, the higher the spray pressures which can be used. However, it is also desireable that the sprays be slightly offset to provide motion of various portions of the garment. Furthermore, the nozzles are preferably oriented to spray at an angle to the garment (preferably, 30 to 40 to the horizontal), better to remove loosened dirt without forcing it back into the garments.

The garments, on conveyor 97, dripping wet from the spray zone, then proceed to the drying zone 26,

which may be simply a hot air tunnel. For a 12 minute cycle time in the drying zone, a convenient conveyor speed of i2 1% inches per minute and garment spacing of 2 in inches is maintained on conveyor 97. For noiron garments, having a heat-set press (cf. the polyester fibers in blends of 65 percent polyester, 35 percent cotton and higher polyester levels), the garments are preferably exposed in this drying zone to the mean temperature between the highest soak or wash spray temperature (160195F) and their heat set temperature (generally on the order of 385-4l5F). In addition to heat, there may also be provided a high humidity (which may be supplied partially or entirely from the moisture on the entering garment, or supplemented by additional added steam), and preferably some flow of air (e.g., downward). Exposing synthetic heat-set fibers to high temperatures under, very humid conditions relaxes the fibers and causes them to go back to the fully pressed form in which they were originally heat set. Very little agitation will be necessary because all prior procedures have been of the type tending to dewrinkle. All upstream temperatures, for example, including soak and spray, are in excess of any tempera tures at which wrinkles were likely to have been set during wear.

Because of the high temperatures, the garments, on exiting the drying zone, even if still quite moist, can flash dry" in the lower relative humidity of the cooler, drier ambient atmosphere. Thus, although it was necessary to utilize energy to provide high temperature, in the drying zone, there is no cost in energy to remove that moisture. In addition, the cooling effect brought about by flash evaporation cools down the fabric so that it will assume no further wrinkles and additionally is suitable for immediate handling.

From conveyor 97 now at 90 inches per minute, and at 1th inches separation, the dried garments are fed to junction M ll), which either sends the garments to a folding station or to a hanging make-up station 31, depending on customer preference. Each garment, or merely the first and last garment of each customer, may have a simple either-or signal, applied, e.g., to the hanger at the hanging station, and now read out by appropriate means of junction Mil. Or, junction 140 may be operated from console 51, by reason of the serial order of the garments, by utilizing a counting device to determine which direction each garment is to take. If the garments are to be delivered on a hanger, the worker at hanging make-up will check to make sure that there are no garments that have to be changed because the inspector or hanger marked them as torn or worn out. The described laundering system can eliminate repair sections, since it will be more economical to replace the few garments that are torn or abused, in view of the lack of abuse to garments in the system.

It may be unnecessary to provide both a folding zone and a hanging make-up zone if a processor elects merely either a folding station or a hanging make-up station. Since the hangers used throughout the continuous garment system are disposable, they will either be folded with and within the garment or will be the hangers on which the garment is delivered to the customer.

If the garments are to be delivered folded, the appropriate folding station for the particular garment type (long coats and dresses, short coats, shirts and smocks, or pants) may be determined by means of a coded signal on the hanger or conveyor or, as shown in FIGS. 1 and 8, by means of a simple photoelectric detecting system. As there shown, beam M2 between a photo-optic beam or light source 1143 and a photocelltype sensor 144 is arranged at hanger level and beam 146 between a photo-optic beam or light source 147 and a photocell-type sensor 148% is arranged below short coat (shirt) level and above long coat (laboratory coat) level. When both beams are interrupted, a signal will be produced which will open gate 150 to lead the garment to the long coat folder 34. If beam 142 only is interrupted, a different signal will be produced to open gate 152 but not gate 150, so as to admit the garments to the short coat fold station 33. When only beam M6 is interrupted, neither gate 150 nor gate 152 will open, allowing trousers to pass to pants folder 32,

The garment sequence, in this embodiment, is maintained through the conventional folding machines. Each machine has excess capability over the system (i.e., can handle in excess of the total system output of 300 garments/hour).

Thus, customer segregation, and serial order at the other end of the folding machines will be maintained because of the equal path lengths and total garment travel time between junction 140 and conveyor belt 156 through the folding machines, the excess machine capacity, and the approximately equal machine speed. However, serial order may also, or alternatively (if the machines are slower) be maintained by precoding numbers onto the hangers, and feeding folded garments along routes 166, 167, 168, shown in FIG. 1 in dotted outline, thus initially by-passing conveyor 1156, to a readout merger gate which will select garments from a route 166, 167 or 168 according to the serial numbers of the garments, and then feed the garments in serial order onto conveyor 156.

Folded garments are merged onto conveyor belt I56 are fed into a conventional plastic bag packaging machine 36 for packaging of individual garments, in serial order. Individual packaged garments can then be assembled by a make-up worker, and garments marked as being in need of repair or replacement diverted and replaced. Make-up is facilitated by coding done initially at the hanging station, in identifying the first and last garments of each customer. Such coding may be integrated with a mechanical signal, e.g., a noise, at the make-up station to alert the make-up worker that a customer batch is beginning or terminating. Since flow from the check-in station to the packaging and makeup station did not interrupt the sequence of the garments which were hung by customer account, make-up will be very simple and quick.

The washing-on-a-hanger system allows for substantial variation in the construction of each particular zone, without departing from the spirit of the invention. For example, in the hanging zone, instead of conveying garments past the check-in worker, a mechanism can be employed to hold the hanger in a set position while the operator is hanging the garment, which will release when the garment is on the hanger by virtue of the weight of the garment.

In the soak zone, in lieu of the conveyored soak tank 62 of FIG. 4, there is shown in FIG. 9 an alternate tank in the form of a J-tank having a high entrance side 176 and a low exit side 177. The garments are fed over a lip 17%, which may be similar to lip 68 of soak tank 62, and are pre-wetted by sprayers 64. In lieu of the conveyor of tank 62, a slick rail 180 extends through J tank, for receiving the hangers from conveyor 61 and supporting the hangers in tank 175. The weight of arriving garments at entrance side 176 forces the previous garments vertically down, through the soak fluids 181 and out the exit side 177, where the hangers are passed to conveyor 90. The same garment rate as described for soak tank 22 may be maintained through J-tank 175.

It is also conceived that, in lieu of soak tanks 62 or 175, a spray zone could be used in which a soft, rainlike spray of continuously recirculated soak liquids, in a confined chamber, gently soaks garments passing slowly therethrough to loosen dirt.

In the spray zone, in lieu of or in combination with the rotating spray rods shown in FIGS. and 6, other arrangements, some of which are schematically illustrated in Figs. it and 11, may be employed. FIG. shows a vertical conveyor means 184, for moving garments slowly up between fixed spray assemblies 185, 186, each of which has a plurality of nozzles 188 arranged, as are the nozzles 100 of FIGS. 5 and 6, substantially in opposition to prevent dirt force-through but somewhat offset to allow for relative garment movement. It may be preferable to have nozzles 188 generally pointing down at an angle, although in some cases (e.g., to get under sleeves) some or all of the nozzles might point at an upward angle. In FIG. 11, the garments are moved slowly on horizontal conveyor 189 between fixed spray assemblies 190, 191, arranged transverse (or vertically) to the direction of garment travel and, as with assemblies 185, 186, arranged to completely cover the exposed garment area, with nozzles 192 arranged similarly to nozzles 188.

In another variation the rods 98a, 98b shown in FIG. 5 could be arranged for rotation not as shown but about their longitudinal axes in a 90 arc in each direction away from the plane of the garment. The rods would be arranged parallel to each other, and along the direction of garment travel and rods on opposite sides of the garment and the nozzles thereon arrangedto provide substantially opposed, but also somewhat offset sprays. In other variations it is conceived that spray assemblies, such as rods 96a, 98b, could be arranged, in lieu of rotating, to move up and down, or back and forth across the garment. Or, in lieu of the illustrated spray rods, lawn-sprinkler type sprayers could be used.

Additional spray stations may also be provided, such as a sterilizing station to apply a bacteria-destroying substance to garments passing therethrough.

If, in addition, the entire process, from check-in to packaging, is carried out in a controlled environment (e.g., an enclosed system from which lint and the like is continuously filtered) using high wash temperatures l90-00F) and even higher drying temperatures (at least 300F and even up to 350F) a sterile garment can be produced. Since the sealed packaging may also be carried out in a controlled environment, which is possible since all these zones from the soak on require no human intervention, one can obtain a sealed sterile product that will not even be contaminated by the atmosphere.

It is conceived that the spray system may possibly be run, for some soil conditions, with no chemicals and no soaps-the heat, soak, and spray action serving to remove all dirt and soil. Minimally, detergent and soap concentration can be cut down over that used in present systems without hurting the cleaning potential or ability. Further it is conceived that one or both of the pre-spotting zone and soak tanks can be eliminated, leaving all washing to be done in the spray zone.

This laundering and finishing system offers a number of advantages over previous systems. Of primary importance, is the substantial reduction in pollutant discharge achieved by the unique washing zone recirculation system. Because the different steps-soaking, spraying with a detergent or other soaps or chemicals, or bleach, or rinsing-are all separate, and the liquids of each station may be kept separate, liquids can be reused-and thus water input, and accordingly pollutant water output significantly reduced. In addition to lowering the total volume of sewage thus discharged, which eases disposal problems, what is discharged is highly concentrated and thus easy to clarify into solids and liquids portions, or to further treat so as to produce substantially pollution free liquid discharges. Furthermore, it is conceived that the lower total volume of detergent which will be necessary (even the possible elimination of the need for detergents) may ultimately be the most significant pollution reducer.

Economically, a very significant reduction in total labor costs, a 50 percent or more reduction in manhours in comparison to other current systems can be achieved. At the same time, since workers will not be required to handle wet or chemically treated garments, or to work under uncomfortable conditions, the working will be more pleasant than that of present systems. Water and sewage charges are reduced because of recirculation, filtration, and reuse of materials. The hardware needs for the entire system are simple, likely to be less expensive than previous hardware, and are totally versatile. Thus, the system will process together: whites and colors; heavy soil and light soil; all types of garments such as shirts, pants, coveralls, dresses, short and long coats, vests, culottes, etc., all types of garment stain conditions whether emanating, e.g., from restaurants, garages, laboratories, or hospitals; and, no-iron (e.g., made of memory fibers) and conventional garments. Using the illustrative conveyor speeds and garment spacings and the resultant component dimensions required to provide necessary cycle times, the entire illustrative system, exclusive of the make-up and recycling areas can be installed within a total plant space of 40 X feet or about 2,500 square feet, which requirement may be even further reduced by stacking components and further minimizing conveyor lengths. In addition, by checking in and hanging soiled garments by customer and maintaining customer segregation during the complete process from washing to packaging, the make-up of the order to be delivered to a customer is simplified and, in comparison to other systems, practically eliminated.

Furthermore, the system provides improved removal of stain and dirt. Pre-spotting of troublesome stains, which is not possible with other systems, is now feasible and practical. The system makes possible the maintenance of a good white because of a minimum of dirt redeposit or force-through. Color loss, if it occurs, will not result in color transfer. Any number of special solvents may be incorporated in a great many places in the system to release or remove troublesome stains.

The soak tank spray system, particularly due to the lack of mechanical action therein, significantly retards wearing down of fabrics. in linen supply or garment rental, since a garment is generally only worn for 4 to 8 hours between washings, wear during washing is a significant factor in average garment wear life.

The system is also particularly suited for no-iron type garments, in that it allows one to take advantage of fibers having an imposed memory with the result that the expensive and slow pressing segment of present laundry cycles can be eliminated.

Other embodiments will occur to those skilled in the art and are within the following claims.

What is claimed is:

1. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, a drying zone, and a conveyor network extending from said hanging zone through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in said zones,

said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge said garments in the same serial order so that wrinkle-free garments originating from different sources of soiled garments are not mixed said conveyor system including at least one conveyor line extending through said washing zone adapted to carry said garments with the long direction of the hangers aligned with the direction of said conveyor line, and said washing zone includes a series of successive separate spray stations through which the garments are successively conveyed in cluding at least one wash station and one rinse station, each said spray station adapted to direct liquid spray in the transverse direction against the broad sides of the successive freely hanging garments in the manner that relative movement between garment and spray causes agitated movement of garment portions while thoroughly subjecting the garment to said spray.

2. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, a drying zone, and a conveyor network extending from said hanging zone through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkie-free drying in said zones,

said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge said garments in the same serial order so that wrinkle-free garments originating from difierent sources of soiled garments are not mixed and wherein said conveyor system includes a first conveyor line extending beyond said hanging zone adapted to carry said garments oriented with the long directions of the hangers at right angles to the said conveyor line, and a second conveyor line extending through said washing zone adapted to carry said garments with the long direction of the hangers aligned with the direction of the second conveyor line, and said washing zone includes a spray zone comprising spray assemblies positioned along the broad sides of the thusoriented garments, defining a plurality of spray stations includ ing wash and rinse stations.

3. The laundering system of claim 1 wherein the last spray station through which the garments are successively conveyed is a fresh water rinse.

4. The laundering system of claim 2 wherein said second conveyor line and said spray assemblies are cooperatively arranged to provide relative movement between the water spray assemblies and the garments during washing.

5. The laundering system of claim 11 wherein said spray stations comprise spray assemblies mounted to rotate in a plane that extends generally parallel to the plane of the garment while spraying said garment.

6. The laundering system of claim 1 wherein each said spray station comprises a plurality of parallel spray lines.

7. The laundering system of claim 1 wherein a said spray station comprises a plurality of nozzles arranged to provide overlapping spray zones sized to cover completely the exposed surfaces of said garment.

8. The laundering system of claim 1 wherein said conveyor line includes timing means for stopping said garment adjacent a spray station for a predetermined spraying time.

9. The laundering system of claim b wherein said predetermined spraying time is in the order of 60 seconds or less.

10. The laundering system of claim l wherein a said spray station comprises spray assemblies, one said spray assembly is mounted on each of the two broad sides of said garment for simultaneous action thereupon, said assemblies being arranged at least partially opposed to one another.

11. The laundering system of claim 2 wherein said second conveyor line comprises multiple parallel conveyors, defining separate routes through said washing zone, divider means for dividing the garments in the preceding first conveyor line into said multiple conveyor lines, a single third conveyor line beyond said washing zone, and merger means following said washing zone for merging the garments onto said third con veyor line in order identical to that of said first conveyor line.

12. The laundering system of claim ll wherein said washing zone also includes a soaking zone preceding said divider means, said soaking zone serving all of said parallel routes through said spray zone.

13. The laundering system of claim ll wherein said drying zone follows said merger means, said drying zone serving all of said parallel routes through said spray zone.

14. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, comprising a spray zone having water spray assemblies, a drying zone, and a conveyor network extending from said hanging station through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in said zones,

said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge said garments in the same serial order so that garments originating from different sources of soiled garments are not mixed,

and

said laundering system adapted to vary the spacing of said garments on said conveyor network as said garments proceed through said system, including maintaining the garments close together in a stage preceding said washing zone, and separating said garments further apart along the direction of travel during said spray zone to enable relative movemerit between the garment and said water spray assemblies, said spray assemblies comprising a series of successive separate spray stations through which the garments are successively conveyed including at least one wash station and one rinse station, each said spray station adapted to direct liquid spray in the transverse direction against the broad sides of the successive freely hanging garments in the manner that relative movement between garment and spray causes agitated movement of garment portions while thoroughly subjecting the garment to said spray.

15. The laundering system of claim 14 including a prespotting zone between said hanging zone and said washing zone for applying a spot-loosening solution to spots on hanging garments, and a delaying zone allow ing said spot-loosening solution to act upon said spots.

16. The laundering system of claim 14 wherein said washing zone includes a soak zone preceding the washing zone for subjection of the garments to a soaking solution, and means for maintaining successive hanging garments with their broad surfaces closely adjacent one another as they proceed through said soak zone.

17. The laundry apparatus according to claim 1 characterized in that said spray stations include spray nozzles on both broad sides of the garment, said spray nozzles being offset from alignment with each other to influence said agitated movement.

18. The, laundry system of claim 1 characterized in that the conveyor is adapted to move relative to said spray stations while said sprays are activated to provide at least one component of said relative motion with reference to said spray.

19. The laundry system of claim 1 characterized in that said spray stations include nozzles which rotate in at least one direction to progressively vary the spray coverage of the broad side of the garment.

20. The laundry system of claim 1 characterized in that said plurality of stations includes a plurality of detergent spray stations and a plurality of rinse stations inclu a final clean rinse statio l. e laundry system accord mg to claim 1 characterized in that a soak zone precedes said washing spray stations.

22. The laundering system of claim 1 characterized in that said conveyor through said washing spray stations comprises multiple parallel conveyors, defining separate lanes through said spray stations, divider means for dividing the garments in a preceding first conveyor line into said multiple conveyor lanes, a single third conveyor line beyond said washing spray stations, and merger means for merging the garments onto said third conveyor line in order identical to that of said first conveyor line.

23. The laundering system of claim 22 characterized in that a soaking zone precedes said divider means, said soaking zone serving all of said parallel lanes through said washing spray zone.

24. The laundering system of claim 22 characterized in that said drying zone follows said merger means, said drying zone serving all of said parallel lanes through said spray zone.

Dedication 3,686,899.H0'wa1"d Rosenfeld, New York, N.Y., and J ustz'u J. Wetzlew, Evanston, I11. LAUNDERING SYSTEM. Patent dated Aug. 29, 1972. Dedication filed July 21, 1978, by the assignees, LuaZeZZ Mfg. 00., Inc. and Amem'cam Linen Supply 00. Hereby dedicate to the Public the remaining term of said patent. [Ofiicz'al Gazette August 22, 1.978.]

UNl'lEl) STATES PATENT @FFHIE QE'ii'ilfiA'liE @F ACQ RRECTA'QN Patent No, 3,68 ,899 Dated August 231972 Inventofls) Howard Rosenfeld and Justin J. wetzler It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

flower Sheet, Item 73 Assignee, "The Linen Supply Association of America, Miami Beach, Fla."

should read ---One--half to A-T-O Inc.,

Willoughby, Ohio; and ome -half to American Linen Supply Co., Minneapolis, Minnesota";

field A, line 2 the "the after "invention" should be deleted line 9, "cutaway" should be ---cut-a-way-;

Col lihe 60,, "(ISO-00F. should be -(190-200Fa)-.,

Signed and. sealed this 5th dayof February 1974.

s. (SELA) Attest:

EDWARD M.FLETCHER,JR. RENE D. TEG'lMEYER Attesting Officer Acting Commissioner of Patents FORM PO-105O (10*690 USCOMM-DC 6O376-P69 u,s. GOVERNMENT PRINTING OFFICE I969 o-aes-au 

1. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, a drying zone, and a conveyor network extending from said hanging zone through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in said zones, said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge saId garments in the same serial order so that wrinkle-free garments originating from different sources of soiled garments are not mixed said conveyor system including at least one conveyor line extending through said washing zone adapted to carry said garments with the long direction of the hangers aligned with the direction of said conveyor line, and said washing zone includes a series of successive separate spray stations through which the garments are successively conveyed including at least one wash station and one rinse station, each said spray station adapted to direct liquid spray in the transverse direction against the broad sides of the successive freely hanging garments in the manner that relative movement between garment and spray causes agitated movement of garment portions while thoroughly subjecting the garment to said spray.
 2. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, a drying zone, and a conveyor network extending from said hanging zone through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in said zones, said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge said garments in the same serial order so that wrinkle-free garments originating from different sources of soiled garments are not mixed and wherein said conveyor system includes a first conveyor line extending beyond said hanging zone adapted to carry said garments oriented with the long directions of the hangers at right angles to the said conveyor line, and a second conveyor line extending through said washing zone adapted to carry said garments with the long direction of the hangers aligned with the direction of the second conveyor line, and said washing zone includes a spray zone comprising spray assemblies positioned along the broad sides of the thus-oriented garments, defining a plurality of spray stations including wash and rinse stations.
 3. The laundering system of claim 1 wherein the last spray station through which the garments are successively conveyed is a fresh water rinse.
 4. The laundering system of claim 2 wherein said second conveyor line and said spray assemblies are cooperatively arranged to provide relative movement between the water spray assemblies and the garments during washing.
 5. The laundering system of claim 1 wherein said spray stations comprise spray assemblies mounted to rotate in a plane that extends generally parallel to the plane of the garment while spraying said garment.
 6. The laundering system of claim 1 wherein each said spray station comprises a plurality of parallel spray lines.
 7. The laundering system of claim 1 wherein a said spray station comprises a plurality of nozzles arranged to provide overlapping spray zones sized to cover completely the exposed surfaces of said garment.
 8. The laundering system of claim 1 wherein said conveyor line includes timing means for stopping said garment adjacent a spray station for a predetermined spraying time.
 9. The laundering system of claim 8 wherein said predetermined spraying time is in the order of 60 seconds or less.
 10. The laundering system of claim 1 wherein a said spray station comprises spray assemblies, one said spray assembly is mounted on each of the two broad sides of said garment for simultaneous action thereupon, said assemblies being arranged at least partially opposed to one another.
 11. The laundering system of claim 2 wherein said second conveyor line comprises multiple parallel conveyors, defining separate routes through said washing zone, divider means for dividing the garments in the preceding first conveyor line into said multiple conveyor lines, a single third cOnveyor line beyond said washing zone, and merger means following said washing zone for merging the garments onto said third conveyor line in order identical to that of said first conveyor line.
 12. The laundering system of claim 11 wherein said washing zone also includes a soaking zone preceding said divider means, said soaking zone serving all of said parallel routes through said spray zone.
 13. The laundering system of claim 11 wherein said drying zone follows said merger means, said drying zone serving all of said parallel routes through said spray zone.
 14. A laundering and finishing system for no-iron garments collected from a number of user sources of soiled garments comprising in combination a hanging zone, a washing zone, comprising a spray zone having water spray assemblies, a drying zone, and a conveyor network extending from said hanging station through said washing and drying zones, said conveyor network adapted to support individual garments on hangers to hang loosely for washing and wrinkle-free drying in said zones, said hanging zone arranged to enable a worker to hang soiled garments from one user source at a time in serial order upon an initial conveyor of said conveyor network, and said conveyor network adapted to discharge said garments in the same serial order so that garments originating from different sources of soiled garments are not mixed, and said laundering system adapted to vary the spacing of said garments on said conveyor network as said garments proceed through said system, including maintaining the garments close together in a stage preceding said washing zone, and separating said garments further apart along the direction of travel during said spray zone to enable relative movement between the garment and said water spray assemblies, said spray assemblies comprising a series of successive separate spray stations through which the garments are successively conveyed including at least one wash station and one rinse station, each said spray station adapted to direct liquid spray in the transverse direction against the broad sides of the successive freely hanging garments in the manner that relative movement between garment and spray causes agitated movement of garment portions while thoroughly subjecting the garment to said spray.
 15. The laundering system of claim 14 including a prespotting zone between said hanging zone and said washing zone for applying a spot-loosening solution to spots on hanging garments, and a delaying zone allowing said spot-loosening solution to act upon said spots.
 16. The laundering system of claim 14 wherein said washing zone includes a soak zone preceding the washing zone for subjection of the garments to a soaking solution, and means for maintaining successive hanging garments with their broad surfaces closely adjacent one another as they proceed through said soak zone.
 17. The laundry apparatus according to claim 1 characterized in that said spray stations include spray nozzles on both broad sides of the garment, said spray nozzles being offset from alignment with each other to influence said agitated movement.
 18. The laundry system of claim 1 characterized in that the conveyor is adapted to move relative to said spray stations while said sprays are activated to provide at least one component of said relative motion with reference to said spray.
 19. The laundry system of claim 1 characterized in that said spray stations include nozzles which rotate in at least one direction to progressively vary the spray coverage of the broad side of the garment.
 20. The laundry system of claim 1 characterized in that said plurality of stations includes a plurality of detergent spray stations and a plurality of rinse stations including a final clean rinse station.
 21. The laundry system according to claim 1 characterized in that a soak zone precedes said washing spray stations.
 22. The laundering system of claim 1 characterized in that said conveyor through said washing spray stations compriSes multiple parallel conveyors, defining separate lanes through said spray stations, divider means for dividing the garments in a preceding first conveyor line into said multiple conveyor lanes, a single third conveyor line beyond said washing spray stations, and merger means for merging the garments onto said third conveyor line in order identical to that of said first conveyor line.
 23. The laundering system of claim 22 characterized in that a soaking zone precedes said divider means, said soaking zone serving all of said parallel lanes through said washing spray zone.
 24. The laundering system of claim 22 characterized in that said drying zone follows said merger means, said drying zone serving all of said parallel lanes through said spray zone. 